Non-slick surface-seeded aggregate concrete and method of forming

ABSTRACT

A non-slick surface-seeded exposed aggregate concrete product and method of making the same enhances the coefficient of friction of an exposed surface thereof to reduce undesirable slipping and sliding. Implementations of the present invention are characterized by the use of fine sand and aggregate broadcast over the exposed surface, which surface has been prepared to receive the same. After curing, the exposed surface is then ground and acid-etched to define fissures, cracks, and/or sharp edges of the aggregate. Subsequently finishing steps are performed to produce the non-slick concrete product which may be used for high traffic pedestrian areas where foot gripping and traction are important, such as on stairs, ramps, walkways, courtyards, and the like.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

the present invention relates to exposed aggregate concrete and, moreparticularly, to an improved non-slick surface-seeded exposed aggregateconcrete and method of producing the same.

as is well known, concrete is extensively utilized as a buildingmaterial for industrial, commercial, and residential applications. Dueto its durability, wear resistance and cost economy, concrete has gainedwidespread use in flooring applications. With this widespread use,Applicants have developed various improvements in concrete flooringproducts and methods of forming such products. Exemplary improvementsinclude variations in color and surface texture of concrete such thatthe concrete possesses the aesthetics typical of more costly flooringsurfaces such as marble, stone and granite.

In developing innovative improvements to concrete flooring products,Applicants have created many new types of surface-seeded exposedaggregate concrete products and methods of forming the same. Generally,such products are produced by first pouring concrete and thenbroadcasting or seeding a mass of hard, inert aggregate materials suchas sand or gravel over the top surface of the concrete and subsequentlytroweling the aggregate into the top surface. The aggregate adheres tothe concrete and is therefore exposed on the top surface when theconcrete cures.

Prior to Applicants' improvements, the surface-seeded exposed aggregatetechnique required aggregates having a mean size of approximatelythree-eighths of an inch in diameter or larger. Such large aggregatesize was necessary in order to provide sufficient adhesion to theconcrete upper cement surface and provide a rough surface to theconcrete. Unfortunately, such large aggregate size also limited thewidespread use of the technique in flooring applications.

Applicants recognized this deficiency and developed a method toeffectively reduce the size of the aggregate exposed on the surface ofthe concrete, as disclosed in U.S. Pat. No. 4,748,788 entitled “SurfaceSeeded Exposed Aggregate Concrete and Method of Producing Same” (issuedJun. 7, 1988), hereby incorporated by reference in its entirety.Applicants improved method for producing a decorative slab was comprisedof pouring a concrete mixture over a prepared sub grade, finishing theupper surface of the mixture with a bull float, spreading a layer ofaggregates less than ⅜ inch in diameter over the mixture, and mixing thetwo together, applying a chemical retarders, and washing and curing themixture. The resulting exposed aggregate concrete surface providedimproved aesthetics and wear resistance qualities similar to that whichis provided by granite, marble or stone flooring.

Applicants later recognized other challenges and developed furtherimprovements to surface-seeded aggregate concrete products. Inparticular, Applicants developed specific improvements to theabove-described technique in Applicants' U.S. Pat. No. 4,748,788. Thisrefined technique, described in Applicants' U.S. Pat. No. 6,016,635,entitled “Surface Seeded Aggregate and Method of Forming the Same”(issued Jan. 25, 2000), facilitated a more uniform top surface textureand greater adhesion of the aggregate thereto and also disclosed the useof glass bead and silica sand as aggregate materials.

Applicants then expanded the variety colors and texture appearances ofconcrete surfaces produced by the methodology of the surface-seededexposed aggregate technique of the prior invention. However, onelimitation on the variety of surfaces producible was thenon-compatibility of certain materials in the concrete mixture. Morespecifically, scientists reported the occurrence of certain chemicalreactions between materials which, over time, degraded the surface. SeeMcConnell et al. “Cement-Aggregate Reaction in Concrete,” J. An.Concrete Inst., V11. 19, No. 2, p. 93 (1947). Siliceous materials foundin concrete aggregate were known to react with alkalis in Portlandcement, creating siliceous gels which lead to expansion, cracking andexudations upon exposed surfaces.

As a result, concrete specifications now typically limit the alkalicontent in cement to 0.6% in order to inhibit such reactions in concreteaggregates. Minerals other than silicates found in concrete aggregateappear to react to an insignificant extent and are usually deemedinnocuous. In response to these problems, Applicants developed a methodof precluding the adverse effects of the potential chemical reactionsbetween desired exposed materials in the concrete mixture which isdisclosed in Applicants' U.S. Pat. No. 6,033,146, entitled “Glass ChipLithocrete and Method of Use of Same” (issued Mar. 7, 2000), herebyincorporated by reference in its entirety.

More recently, additional drawbacks associated with concrete flooringproducts have come to light in certain high traffic areas where footgripping and traction are important. Such high traffic areas includestairs, ramps, walkways, courtyards, and the like. In particular,various exposed aggregate concrete products may have a slick surfacefinish which may be undesirable for these high traffic areas. Althoughslick surface finishes may usually be safe, materials that form slightsurface films, such as liquids, dust, dirt, or other such contaminantsmay lessen the traction of slick surface finishes. The result is a lackof proper grip or traction, which may cause an individual to slide orslip while walking thereupon.

In order to mitigate the risks associated with slick surface finishes,grip strips or tread strips have been used to increase the traction andfriction of such surfaces. For example, adhesive floor friction stripsor traction tread flooring have been used to provide additional tractionfor such surfaces. Adhesive floor friction strips may be adhesivelysecured to the floor and provide a sandpaper-like finish on an exposedportion thereof to enhance the traction of the floor at the location ofthe friction strip. Traction tread flooring typically includes a metalpanel with small raised perforations which contact the sole of anindividual's shoe and create additional grip between the sole and thepanel. Various other types of gripping surfaces may be retrofitted ontoa completed surface in order to improve the traction and frictiongenerated when walking on the surface. Nevertheless, such materialsoften decrease the aesthetic appeal of the floors and because they aremerely additions to the floor, these materials often become dislodged orpeel away from the floor as a result of normal wear and tear.

Thus, there exists a substantial need in the art for an improved exposedaggregate concrete finishing technique which is appropriate forhigh-pedestrian-traffic flooring applications in that the surface hasimproved traction. There is a need in the art for an attractive flooringsurface that does not require the addition of traction-enhancingmaterials in order to properly ensure adequate traction and gripping onthe surface. Finally, there exists a need in the art for a method ofproducing such surface-seeded exposed aggregate concrete product thathas a non-slick surface finish.

BRIEF SUMMARY

A non-slick surface-seeded exposed aggregate concrete product and amethod of producing the concrete product upon a sub grade or structureare provided. The method comprises the steps of: pouring a concretemixture over the sub grade, the concrete mixture defining an exposedsurface when poured; finishing the exposed surface of the concretemixture to dispose a quantity of cement/fines paste derived from theconcrete mixture at the exposed surface; broadcasting a quantity ofaggregate upon the exposed surface of the concrete mixture; mixing theaggregate into the cement/fines paste; grinding the exposed surface ofthe concrete mixture; etching the exposed surface, for example, bysandblasting or by applying an acid solution thereto to acid etch theexposed surface; and applying a sealer to the exposed surface.

According to an embodiment of the present invention, the grinding stepmay include using a concrete grinder. The grinding step may also includegrinding the exposed surface to have variable depths. Theapplying-the-acid-solution step may include applying muriatic acid tothe exposed surface. Further, the applying-the-acid-solution step mayalso include brushing the exposed surface with a scrubbing device. Themethod may also include a step of rinsing the exposed surface afterapplying the acid solution to remove the acid solution there from. Infact, the applying the acid solution step may also include the step ofallowing the acid solution to etch the exposed surface for at least fiveminutes prior to removal. The step of rinsing the exposed surface mayinclude applying water to the exposed surface of the concrete mixture.

In addition, the method may further include utilizing a vibrating metalbull float to dispose a quantity of cement/fines paste derived from theconcrete mixture at the exposed surface. Furthermore, the mixingaggregate step may include utilizing a vibrating metal bull float to mixthe aggregate into the quantity of cement/fines paste. The mixing andfinishing steps may also comprise using hand floats, trowels and powertrowels to cover said aggregate with said cement/fines paste.

In addition, the method may also including the steps of: washing surfacefilms from the exposed surface; curing the concrete mixture and thecement/fines paste to form a cured mixture and a cured paste; andwashing the exposed surface to remove surface residue there from. In animplementation of the present invention, the broadcasting step of themethod may include broadcasting fine sand of a given color onto theexposed surface to produce the simulated appearance of quarried stone.Likewise the broadcasting step may also include broadcasting aggregateor reactive aggregate of a given color and any size onto the exposedsurface to produce the simulated appearance of quarried stone. Integralaggregate and sands may also be used for the ground and acid etchedfinish.

Furthermore, the broadcasting step may also include broadcasting finesand of a given color and aggregate of another given color onto theexposed surface to produce the simulated quarried stone appearance. Inthis regard, the color of the fine sand and the aggregate may becoordinated to produce the desired appearance. Finally, the method mayalso include the step of producing a pattern on the exposed surface in amanner to produce the simulated appearance of quarried stone.

BRIEF DESCRIPTION OF THE DRAWINGS

these as well as other features of the present invention will becomemore apparent upon reference to the drawings wherein:

FIG. 1 is a perspective view illustrating stages of preparation of anon-slick surface-seeded exposed aggregate concrete product produced inaccordance with an embodiment of the present invention; and

FIG. 2 is schematic diagram illustrating steps of a method for producingthe non-slick concrete product in accordance with another embodiment ofthe present invention.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes ofillustrating the preferred embodiments of the invention only, and notfor purposes of limiting the same, FIGS. 1-2 illustrate an improvedsurface-seeded exposed aggregate having a non-slick surface finish andthe method of producing the same. Preferred embodiments of the methodutilize surface-seeded exposed aggregate disposed upon a sub grade 10,similar to several of the above-mentioned methods. However, the presentmethod incorporates a novel and non-obvious method of producing anon-slick finish on a surface-seeded exposed aggregate concrete productwithout the use of floor traction products such as adhesive floortraction strips, metal grates, or traction tread flooring.

As will be appreciated by those of skill in the art, as well as thosewho will use the product and method described herein, the embodiments ofthe present invention alleviate several of the drawbacks of priorsurface-seeded exposed aggregate concrete products and methods. Inparticular, embodiments of the present invention provide a desirablesurface finish having a higher coefficient of friction. With this highercoefficient of friction, individuals who walk on the concrete productwill be able to have sure and steady grip without slipping or sliding.

Thus, the concrete product of embodiments of the present invention has anon-slick surface that is an important attribute for high traffic areaswhere foot gripping and traction are very important, such as on stairs,ramps, walkways, courtyards, and the like. The teachings herein may alsobe used to modify existing floors to enhance their coefficients offriction as well. Indeed, it is contemplated that various embodimentsand implementations of the present invention, whether concrete productor method of making the same, may be utilized in a broad variety ofsettings and applications.

An implementation of the present invention may be performed afterproperly preparing the sub grade 10, which may be performed in a varietyof ways, utilizing a variety of tools, materials, and methods. One suchconventional mode of preparation, as shown in FIG. 2 as the initial stepin the method of the present invention, comprises the preparation of thesub grade 10 to a desired elevation and grade and to compact the samepreferably a desired compaction level such as to ninety percent (90%)compaction. Subsequent to this preparation, the sub grade 10 may becovered with a layer of clean, moist fill sand 16 which is preferablymaintained at a minimum four (4) inch layer thickness.

However, other thicknesses of fill sand 16 may be maintained. Althoughthe fill sand 16 is not absolutely necessary for the method of producingthe simulated quarried stone of the present invention, it is highlydesirable to control the hydration process of the concrete. In order toincrease the resultant strength of the concrete and reduce subsequentcracking of the same, reinforcement members 18 such as a wire mesh orrebar may be positioned upon the layer of fill sand 16. The layer whichincludes the fill sand 16 and the reinforcement members 18 is oftenreferred to as the sub grade 10.

a concrete mixture 20 is poured over the sub grade 10 such that thereinforcement members 18 are encapsulated within the concrete mixture20. The concrete mixture 20 is poured to any thickness and preferably toa thickness of approximately a three and one half (3½) to four (4)inches. Although variations in the concrete mixture 20 are contemplated,a preferred concrete mixture 20 comprises seventy percent (70%) sand andthirty percent (30%) three-eighth (⅜) inch mean diameter aggregatecombined with six sack cement (2,000 pounds per square inch) or sevensack cement (3,000 pounds per square inch). Dependent on individualtastes, various color mixtures can be added to the concrete mixture 20.

after the concrete mixture 20 has been poured, the concrete mixture 20is preferably screeded to a desired level plane or grade. The screedingof the concrete mixture 20 results in the same defining a generallylevel or planer upper exposed surface 22. In the present invention,tamping of the concrete mixture 20 may be omitted in contravention tonormal practices in the art. In this respect, it has been determinedthat tamping should be avoided in implementing embodiments of thepresent invention so as to avoiding bringing up an excess ofcement/fines in the concrete mixture 20 which would be prohibitive forthe subsequent surface seeding of the exposed aggregate.

Rather, subsequent to screeding, the exposed surface 22 of the concretemixture 20 is preferably surfaced or finished to dispose of a quantityof the cement/fine paste derived from the concrete mixture 20 at theexposed surface 22. This finishing may be done utilizing a vibratingbull float or any other suitable means. The vibrating bull float istypically characterized by having an extremely smooth or polishedsurface which, in addition to bringing up the appropriate amount ofcement/fine paste for the subsequent steps of the present invention,also tends to seal the exposed surface 22 of the concrete mixture 20. Itis contemplated that this initial finishing step may be completedthrough the use of a vibrating bull float, such as a vibrating magnesiumbull float or a vibrating aluminum bull float. A preferred metal bullfloat is sold under the trademark HAL200 by the Lievers Holland Co.

According to an aspect of the present invention, as illustrated in FIG.2, when the exposed surface 22 of the concrete mixture 20 is still inthe plastic state, fine sand 12 may be broadcast over the exposedsurface 22. The fine sand 12 may be of any given color or texture, asrequired to produce the simulated appearance of quarried stone. Further,it is contemplated that various combinations of color, texture, or othercharacteristics of the fine sand 12 may be variously created in order toaccurately simulate the appearance of quarried stone. Thus, in someinstances, multiple types of fine sand 12 may be utilized in a givenproject to produce desired aesthetic effects. In other instances, thefine sand 12 may be of a single type.

In this regard, the coloring and/or patterns that may be createdutilizing the fine sand 12 are dependant upon the manner in which thefine sand 12 is broadcast upon the exposed surface 22. The fine sand 12may be utilized to produce an overall shade or color as the simulatedappearance of quarried stone, or may be alternated with other colors ofthe fine sand 12 or quantity thereof to simulate the various aspects ofnatural quarried stone such as graining, fractures, joints, knots,crystallization patterns, sand seams, streaks, subjoints, weathering,and/or rock texture properties such as porphyritic, ophitic, and orei.

In addition to the broadcasting of the fine sand 12, a quantity ofaggregate 14 may also be broadcast upon the exposed surface 22 of theconcrete mixture 20. As mentioned above in relation to the fine sand 12,the characteristics of the aggregate 14, such as the color, texture, orsize, may be varied as required in order to simulate the appearance ofnatural quarried stone. Indeed, in order to simulate the flex, speckles,and inclusions of natural quarried stone, it is contemplated that theaggregate 14 may be selected to contrast with the fine sand 12, oralternatively, that the aggregate 14 may be utilized to complement thefine sand 12 and thereby simulate the appearance of natural quarriedstone.

As is known in the art, quarried stone may be of various types such asgranite, marble, rhinestone, bluestone, and brownstone, to name a few.It is contemplated that the aggregate 14 and fine sand 12 may be matchedin various combinations of color, size, pattern, etc., to produce thevarious effects that natural quarried stone displays such as graining,fractures, joints, knots, crystallization patterns, sand seams, streaks,subjoints, weathering, rock texture properties such as porphyritic,ophitic, and orei, etc. In addition, the quantity of the fine sand 12and/or the aggregate 14 per unit area may also be varied to simulatenatural quarried stone. Finally, it is contemplated that the exposedsurface 22 may be cut to a surface design as required to produce thesimulated appearance of quarried stone. In this regard, the cuts may beperformed according to the requirements of a given project, such asstraight cuts, cuts of any geometry, or cuts to simulate the shape andtexture of natural quarried stone.

According to an implementation of the present invention, it iscontemplated that the broadcasting of the fine sand 12 and the aggregate14 may be performed utilizing pneumatic equipment. In this regard, thepneumatic equipment may allow an operator more precisely and uniformlyplace or spread the fine sand 12 and/or aggregate 14 duringbroadcasting. As was earlier mentioned, the use of pneumatic equipmentmay allow the fine sand 12 and/or the aggregate 14 to be evenlydistributed upon the exposed surface 22. However, it is alsocontemplated that pneumatic equipment may allow the operator to producea randomized pattern or a design corresponding to a particularappearance of natural quarried stone. Thus, the appearance of theexposed surface 22 may be enhanced by utilizing various tools such aspneumatic equipment.

After broadcasting upon the exposed surface 22 of the concrete mixture20, the fine sand 12 and the aggregate 14 are mixed or worked into theexposed surface 22 of the concrete mixture 20, and more particularly aremixed into the cement/fine paste of the exposed surface 22. Inimplementations of the present invention, this step may be utilized tofurther enhance the physical placement of the fine sand 12 and theaggregate 14 on the exposed surface 22. It is contemplated that thisstep may be performed in order to create various effects exhibited bynatural quarried stone displays, such as graining, fractures, joints,knots, crystallization patterns, sand seams, streaks, subjoints,weathering.

In addition, additional effects may be produced such as rock textureproperties such as porphyritic, ophitic, and orei, etc. This may beaccomplished utilizing a power trowel. However, it is contemplated thatthe mixing may be accomplished utilizing other devices known in the art.This mixing of the fine sand 12 and the aggregate 14 with thecement/fine paste at the exposed surface 22 is also critical to theprocess of the present invention because it ensures that the fine sand12 and the aggregate 14 are fully embedded into the cement/fine pasteand thus thoroughly adhered or bonded to the exposed surface 22 of theconcrete mixture 20 upon resultant curing.

Referring still to FIG. 2, subsequent to the mixing of the fine sand 12and the aggregate 14 into the cement/fine paste at the exposed surface22 of the concrete mixture 20, the exposed surface 22 may be finishedwith a hand or power trowel, a bull float, or a hand float to properlylevel and finish the exposed surface 22. After the exposed surface 22 isfinished, the exposed surface 22 may then be allowed sufficient time tocure.

As illustrated in FIG. 2, subsequent to washing, the concrete mixture 20may be cured utilizing water alone, as opposed to chemical curingagents, in order to avoid staining of the exposed surface 22. Such watercuring may typically be facilitated through the use of a conventionalfogger or soaker hose. After a prescribed period of time (e.g., 30 daysafter initiating the curing process), any surface residue present on theexposed surface 22 may be removed by conventional power washing with anappropriate solution such as a solution of a ninety percent (90%) steamand ten percent (10%) muriatic acid mixture which is applied by a powerwasher via a high pressure nozzle.

Thereafter, a chemical surface retarder may be sprayed upon the exposedsurface 22 to uniformly cover the same. The chemical retarder slows downthe hydration process of the concrete mixture 20. The application of thesurface retarder to the exposed surface 22 may be followed by the stepof finishing the exposed surface 22 of the concrete mixture 20 with thepower trowel, for example, to massage the surface retarder into thecement/fine paste having the fine sand 12 and the aggregate 14 mixedtherein. This finishing step preferably results in the penetration ofthe surface retarder into the cement/fine paste a distance below themaximum depth of the fine sand 12 and the aggregate 14.

The penetration of the surface retarder into the cement/fine paste mayextend to a depth of at least approximately ⅜ inch in some instances.Advantageously, this particular finishing step may eliminate hard spotsin the resulted concrete by facilitating a full mix of the retarder andthe cement fine paste. The power trowel preferably used in relation toboth this and the previously mentioned step finishes the exposed surface22 of the concrete mixture 20 in a generally circular motion. Althoughvarious conventional surface retarders may be utilized, a superiorsurface retarder is designated as SPEC AE manufactured by E.L. Moor Co.of Costa Mesa, Calif.

Referring again to FIG. 2, subsequent to the surface retarder beingmassaged into the cement/fine paste, a vapor barrier may be preferablyformed on the exposed surface 22 of the concrete mixture 20. In thepreferred embodiment, the formation of the vapor barrier is facilitatedby the application of a liquid chemical evaporation reducer to theexposed surface 22 of the concrete mixture 20. A preferred evaporationreducer is sold under the trademark CONFILM by the Concrete Tie Co. ofCompton, Calif. An alternative vapor barrier may be formed by coveringthe exposed surface 22 with four (4) or six (6) millimeters of visquene.The vapor barrier is maintained upon the exposed surface 22 of theconcrete mixture 20 for a prescribed period of time which may range fromapproximately two (2) to twenty-four (24) hours.

When the concrete mixture 20 has cured, the exposed surface 22 thereofmay be prepared by cleaning any particulate or residue therefrom,although cleaning is not required in preparation for grinding. Theexposed surface 22 may then be ground utilizing a conventional rotaryconcrete grinder or other suitable device. A concrete grinder serves tominimize surface irregularities, scrape surfaces, and shear materialfrom the exposed surface 22, as well as to expose the aggregate 14. Theaggregate 14 may be cut or shorn by the concrete grinder. However, thegrinding preferably allows the larger aggregate to maintain a polishedappearance while the smaller aggregate and sand are exposed thereby.Thus, the concrete grinder not only tends to create a level surface, butalso produces small fissures, cracks, and/or sharp edges in theaggregate 14 of the entire exposed surface 22 due to the exposure of thesmall aggregate and sand. The grinding thus serves to increase thecoefficient of friction of the exposed surface 22 to provide a non-slippedestrian surface.

The increased coefficient of friction will tend to cause greatertraction or friction between the exposed surface 22 and an object, suchas a foot or wheel, contacting the exposed surface 22. In this regard,the exposed surface 22 may thus become non-slick. Additionally, thedepth of the grinding may be varied in order to achieve differentappearances. A variable depth may tend to expose differentcross-sections of the aggregate 14 and other details in the exposedsurface 22. The depth of the grinding may be determined and establishedby varying the parameters of the equipment used (grinders/materials).Therefore, the grinding may not only increase the coefficient offriction of the exposed surface 22, but the grinding may also enhancethe appearance of the exposed surface 22.

After the exposed surface 22 has been ground to produce a smooth surfaceand the desired finish and look of the exposed surface 22 has beenachieved, the exposed surface 22 may be prepared for etching. Althoughacid etching is a preferred method, other mechanical methods such assandblasting, shot blasting, scarifying, are also alternatives, to namea few. However, some of the mechanical methods may fracture theaggregate or dull the appearance of the aggregate, which may beundesirable. The etching process should remove small amounts of theconcrete mixture 20 or cement paste from the exposed surface 22, whichwill in turn, tend to emphasize the small and ubiquitous fissures,cracks, and/or sharp edges formed in the aggregate 14. The small amountsof concrete mixture 20 may thus be removed from the regions immediatelysurrounding the aggregate 14 to further define the fissures, cracks,and/or sharp edges of the aggregate 14. The removal of the concretemixture 20 from these small areas will provide additionalmicro-irregularities that will increase the coefficient of friction ofthe exposed surface 22 while maintaining the exposed surface 22 assubstantially flat and suitable for pedestrian traffic. The exposedsurface 22 may therefore become non-slick and prevent the undesirableslipping and sliding characteristics exhibited by exposed aggregateconcrete surfaces of the prior art. Therefore, although acid etching maybe effective in properly etching the exposed surface 22, other methodssuch as sandblasting, shot blasting, and scarifying may also be used.

In order to prepare the exposed surface 22 for etching, any particulateremaining from the grinding should preferably be removed. When acidetching is used, proper guidelines must be followed. Selection of thetype of acid, as well as the monitoring of the pH and other factors maybe performed by one of skill in the art. An acid solution, such asmuriatic (hydrochloric) acid, phosphoric acid, or sulfamic acid may beevenly spread onto the exposed surface 22. The acid solution may bespread using a sprinkler or an acid tolerant spraying device. The acidsolution may then be worked into the exposed surface 22 using ascrubbing device such as a bristle brush. The acid solution may beallowed a short period of time, such as five to ten minutes, to etch theexposed surface 22. Once the etching is completed, the acid solution maythen be rinsed and removed from the exposed surface 22 using a hose tospray water thereon or by a power washer via a high pressure nozzle inorder to thus dilute, neutralize, and remove the acid solution.

The diluted acid solution may also be vacuumed using a wet vacuum. Therinsing of the exposed surface 22 should be repeated as necessary.Extreme care should be taken to ensure that the process is performedwithout causing undesirable chemical reactions, and so that the pH ofthe exposed surface 22 returns to a normal level.

Once the exposed surface 22 has been ground and acid etched, a sealer 24may be used to finish the exposed surface 22. Due to the porous natureof the concrete mixture 20, water, chlorides, stains, and other water oroil-based materials may be absorbed through the exposed surface 22absent the use of the sealer 24. The sealer 24 tends to protect theexposed surface 22 of the non-slick concrete product by preventing theabsorption of such materials without trapping moisture in the exposedsurface 22. The sealer 24 also enriches the appearance of the exposedsurface 22. Further, the sealer 24 is also useful to prevent erosion,staining, abrasion, chipping, and/or of the exposed surface 22, thusensuring that the integrity of the exposed surface 22 is protected. Moreparticularly, due to the small and ubiquitous fissures, cracks, and/orsharp edges formed in the aggregate 14, the aggregate 14 may tendcrumble from the exposed surface 22 without the use of the sealer 24.

The sealer 24 may be a film former, which may advantageously provide agloss or sheen appearance to the exposed surface 22, or a penetrant,which may penetrate up to four millimeters into the exposed surface 22and maintain an unaltered appearance of the exposed surface 22. Thesealer 24 may be selected to achieve the desired surface appearance ofthe exposed surface 22 as well as to facilitate future maintenance. Itis contemplated that various types of sealers 24 may be used forenhancing the attributes, appearance, and friction of the exposedsurface 22.

Advantageously, the resultant non-slick surface-seeded exposed aggregateconcrete not only exhibits an extremely flat exposed aggregate surfacewhich is suitable for flooring applications, but also providessufficient traction for extremely high traffic pedestrian areas wherefoot gripping is important, such as on stairs, ramps, walkways andcourtyards. In this manner, the use of additional floor tractionproducts, such as adhesive floor traction strips, metal grates, ortraction tread flooring, is unnecessary. Furthermore, variousembodiments of the present invention also provide a desirable surfacefinish having a higher coefficient of friction. With this highercoefficient of friction, individuals who walk on the concrete productwill enjoy sure and steady grip without slipping or sliding.

In addition, the surface texture and color of the exposed surface 22 issuch that it approximates the surface color and texture of moreconventional flooring surfaces such as stone, granite and marble. Thisresemblance can be further accentuated by saw cutting the concretesurface into rectangular grids to give the appearance that theindividual rectangular squares of the grid were laid in a manneranalogous to the arrangement of stone, granite or marble flooring. Thus,the present invention comprises a significant improvement in the art byproviding a surface-seeded exposed aggregate concrete that, due to themanipulation of color and size of the aggregate, as well as the grindingof the exposed surface 22, possesses a non-slick surface finish,texture, and color that improves the coefficient of friction andaesthetics of the exposed surface 22.

The above description is given by way of example, and not limitation.Given the above disclosure, one skilled in the art could devisevariations that are within the scope and spirit invention disclosedherein, including various ways of creating different textures, colors,patterns, types of stone, etc. Further, the various features of theembodiments disclosed herein can be used alone, or in varyingcombinations with each other and are not intended to be limited to thespecific combination described herein. Thus, the scope of the claims isnot to be limited by the illustrated embodiments.

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 17. A method of producing non-slick surface-seededexposed aggregate upon a subgrade, the method comprising: pouring aconcrete mixture over the subgrade, the concrete mixture defining anexposed surface when poured; finishing the exposed surface of theconcrete mixture to dispose of a quantity of cement/fines paste derivedfrom the concrete mixture at the exposed surface thereof; broadcasting aquantity of aggregate upon the exposed surface of the concrete mixture;mixing the aggregate into the cement/fines paste; grinding the exposedsurface of the concrete mixture for cutting the aggregate to increase acoefficient of friction of the exposed surface; after the grinding step,etching the exposed surface for emphasizing small fissures, cracksand/or sharp edges formed in the aggregate to increase the coefficientof friction of the exposed surface; and without polishing the ground andetched exposed surface, applying a sealer to the exposed surface. 18.The method of claim 17 wherein the grinding step includes using aconcrete grinder.
 19. The method of claim 17 wherein the grinding stepincludes grinding the exposed surface to have variable depths.
 20. Themethod of claim 17 wherein the etching step includes sandblasting theexposed surface to etch the exposed surface.
 21. The method of claim 17wherein the etching step includes brushing the exposed surface with ascrubbing device.
 22. The method of claim 17 wherein the etching stepincludes applying an acid solution to the exposed surface to acid etchthe exposed surface.
 23. The method of claim 22 muriatic acid is appliedto the exposed surface.
 24. The method of claim 22 further including thestep of rinsing the exposed surface after applying the acid solution toremove the acid solution therefrom.
 25. The method of claim 24 whereinthe etching step includes allowing the acid solution to etch the exposedsurface.
 26. The method of claim 24 wherein the step of rinsing of theexposed surface includes applying water to the exposed surface of theconcrete mixture.
 27. The method of claim 17 further includes utilizinga vibrating float to dispose a quantity of cement/fines paste derivedfrom the concrete mixture at the exposed surface thereof.
 28. The methodof claim 17 wherein the step of mixing aggregate further includesutilizing a vibrating metal bull float to mix the aggregate into thequantity of cement/fines paste.
 29. The method of claim 17 wherein themixing step comprises using a hand float to cover said aggregate withsaid cement/fines paste.
 30. The method of claim 17 further includingthe steps of washing surface films from the exposed surface; curing theconcrete mixture and the cement/fines paste to form a cured mixture anda cured paste; and washing the exposed surface to remove surface residuetherefrom.
 31. The method of claim 17 wherein the broadcasting stepincludes broadcasting at least one of fine sand, aggregate, and reactiveaggregate of a given color onto the exposed surface to produce thesimulated appearance of quarried stone, the color of the fine sand andthe aggregate being coordinated to produce the simulated appearance ofquarried stone.
 32. A surface-seeded exposed particulate concreteproduct formed by the method of claim 17.